Technical Information

Hartridge Ltd., The Hartridge Building, Network 421,

Radclive Road, Buckingham MK18 4FD, United Kingdom
Tel: +44 (0) 1280 825 600
e-mail: sales@hartridge.com
Fax: +44 (0) 1280 825 601
Web: www.hartridge.com
Bulletin No. TIB196/6
Product: HF1134 – VDO Common Rail Pump Kit
HF1136 – VDO Common Rail Pump Kit (Upgrade)
HF1155 – APB309 Upgrade Kit (for VDO 5WS40565)
HF1158 – VDO CR Pump Supplementary Kit (LION)
Subject: Hartridge Fixturing Matrix for VDO Common Rail Pump
Service Solution

1. Introduction
The official authorised VDO Common Rail pump service solution is based on the Hartridge AVM2-PC with HB378
Universal CR Base Kit, HF1130 All Makes Common Rail Pump Test Kit, HF1134 VDO Common Rail Pump Kit
and HF1136 VDO Common Rail Pump Kit (Upgrade), HF1155 APB309 Upgrade Kit for VDO 5WS40565 (If
required) and the HF1158 VDO CR Pump Supplementary Kit (LION) fitted to the test bench.

The pumps that are now covered as part of the official authorised VDO Common Rail pump service solution are:

Part Number Pump Type Application

PSA (PEUGEOT S.A.)
5WS40008 DV4TD
FORD
5WS40018 DW10TD PSA (PEUGEOT S.A.)
5WS40019 DW10B PSA (PEUGEOT S.A.)
FORD
5WS40064 NGD 3.0 FORD
5WS40094 LYNX FORD
5WS40153 K9K_EU4 RENAULT
5WS40157 LION V6 PSA (PEUGEOT S.A.)
JAGUAR
RANGE ROVER
5WS40163 DW10B VOLVO
5WS40254 LION V8 LAND ROVER
5WS40273 LION V6 UG JAGUAR
LAND ROVER
5WS40565 K9K_EU5 RENAULT
5WS40694 PUMA FORD TRANSIT
5WS40695 PUMA FORD RANGER
5WS40698 PUMA
5WS40905 SPRINT SPRINT
A2C53366732 VW VW, AUDI, SKODA,
A2C53341464 SEAT
5WS40893 DV6C FORD, PSA
5WS40894 DV6C FORD, PSA

Please Note: - The example test plans issued in TIB195/07 are not part of the official authorised VDO Common
Rail pump service solution.

TIB 196/6 Issue 8, June 2018 (AT3531) © Hartridge Ltd., 2018 Page 1 of 8
Each pump requires specific Hartridge tooling which is detailed below in the Pump fitting section; each pump
must be fitted in accordance with this.

**HF1136 orders made before July 2013 will require HF1155.

2. Pump Fitting
New parts added are in Bold

DV4TD_5WS40008
VDO Configuration
3 4

1 Mounting APB242 Mounting Plate

2 Coupling ADC95/1 Drive Coupling 20mm Taper

3 Supply ALP323 10mm QR Adaptor

5

4 Return ALP348 Banjo Adaptor

5 HP Outlet - (None)
6 - - (None)
7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

DW10TD_5WS40018
VDO Configuration

4 APB250/1 Mounting Plate

1 Mounting
5 APB250/3 50mm Spigot Adaptor

2 Coupling ADC95/1 Drive Coupling 20mm Taper

3 Supply ALP323 10mm QR Adaptor

4 Return ALP348 Banjo Adaptor

5 HP Outlet - (None)
6 - - (None)
3 7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

TIB 196/6 Issue 8, June 2018 (AT3531) © Hartridge Ltd., 2018 Page 2 of 8
DW10B_5WS40019
VDO Configuration
3
4
1 Mounting APB316 Mounting Plate

ADC298
Service Drive Unit
2 Coupling X39-800-300-
Tang Drive Plate
031Z
3 Supply ALP323 10mm QR Adaptor

4 Return ALP350 8mm Adaptor

5 5 HP Outlet A086B103 90 Deg HP Pipe Assy
6 - - (None)
7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

NGD 3.0_5WS40064
VDO Configuration
3 4
1 Mounting APB250/1 Mounting Plate

2 Coupling ADC95/1 Drive Coupling 20mm Taper

3 Supply ALP323 10mm QR Adaptor

4 Return ALP307 8mm QR Adaptor

5 HP Outlet - (None)
6 - - (None)
7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

5

Screws Pump to plate: 3 off M8x35

LYNX_5WS40094
VDO Configuration
3
Mounting Plate
5 1 Mounting APB299

2 Coupling ADC95/1 Drive Coupling 20mm Taper

3 Supply ALP334 QR Adaptor

4 Return ALP348 Banjo Adaptor

5 HP Outlet - (None)
6 - - (None)

4 7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

TIB 196/6 Issue 8, June 2018 (AT3531) © Hartridge Ltd., 2018 Page 3 of 8
K9K_EU4_5WS40153
VDO Configuration
4

1 Mounting APB309 Mounting Plate

5 2 Coupling ADC299 Coupling 20mm Taper Long

3 Supply ALP307 8mm QR Adaptor

4 Return ALP307 8mm QR Adaptor

5 HP Outlet - (None)
6 - - (None)
3 7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M6x40

LION V6_5WS40157
VDO Configuration
3 4

1 Mounting APB312 Mounting Plate

5

2 Coupling ADC299 Coupling 20mm Taper Long

3 Supply ALP323 10mm QR Adaptor

4 Return ALP348 Banjo Adaptor

5 HP Outlet - (None)
6 - - (None)
7 Cable A086E950 Pump Cable – VDO 1

Drive Direction L (CCW) – viewed from pump drive end

Screws Pump to plate: 4 off M8x80

DW10B (VOLVO) _5WS40163

VDO Configuration
3
4
1 Mounting APB316 Mounting Plate

ADC298
Service Drive Unit
2 Coupling X39-800-300-
Tang Drive Plate
031Z
3 Supply ALP334 QR Adaptor

4 Return ALP350 8mm Adaptor

5 HP Outlet A086B103 90 Deg HP Pipe Assy
6 - - (None)

5
7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

TIB 196/6 Issue 8, June 2018 (AT3531) © Hartridge Ltd., 2018 Page 4 of 8
LION V8_5WS40254
VDO Configuration
4
5 APB242 Mounting Plate
1 Mounting
APB250/3 50mm Spigot Adaptor

6 ADC307 Coupling
+ +
2 Coupling ADC312 Bolt
+ +
ADC313 Spacer
3 Supply ALP323 10mm QR Adaptor

4 Return ALP307 8mm QR Adaptor

3
5 HP Outlet A086B103 90 Deg HP Pipe Assy
6 - A189A412 M12 Blanking Plug
7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

LION V6 UG_5WS40273
VDO Configuration
5

1 Mounting APB250/1 Mounting Plate

2 Coupling ADC95/1 Drive Coupling 20mm Taper

3 Supply ALP323 10mm QR Adaptor

4 Return ALP307 8mm QR Adaptor

6
3 5 HP Outlet A086B103 90 Deg HP Pipe Assy
6 - A189A412 M12 Blanking Plug

4 7 Cable A086E950 Pump Cable – VDO 1

Drive Direction L (CCW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

K9K_EU5_5WS40565
VDO Configuration
6

4 1 Mounting APB309 Mounting Plate

3

2 Coupling ADC299 Coupling 20mm Taper long

3 Supply ALP307 8mm QR Adaptor

4 Return ALP307 8mm QR Adaptor

5 HP Outlet - (None)
6 - ALP363 5th Injector Port

5
7 Cable A086E950 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M6x40

TIB 196/6 Issue 8, June 2018 (AT3531) © Hartridge Ltd., 2018 Page 5 of 8
PUMA_5WS40694
VDO Configuration
3 5
1 Mounting APB349 Mounting Plate
4
ADC298 Service Drive Unit
2 Coupling + +
ADC300 Tang Drive Plate
3 Supply ALP323 10mm QR Adaptor

4 Return ALP307 8mm QR Adaptor

5 HP Outlet A086B103 90 Deg HP Pipe Assy
6 - - (None)

7 Cable A086E955 Pump Cable – VDO 1

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

PUMA_5WS40695 & 5WS40698

VDO Configuration

3 5
1 Mounting APB250_1 Mounting Plate

ADC307 Coupling
+ +
2 Coupling ADC312 Bolt
4
+ +
ADC313 Spacer
3 Supply ALP323 10mm QR Adaptor

4 Return ALP307 8mm QR Adaptor

5 HP Outlet A086B103 90 Deg HP Pipe Assy

6 - - (None)

7 Cable A086E955 Pump Cable – VDO 2

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

SPRINT_5WS40905
VDO Configuration
3
5
1 Mounting APB250_1 Mounting Plate

ADC307 Coupling
+ +
2 Coupling ADC312 Bolt
4
+ +
ADC313 Spacer
3 Supply ALP323 10mm QR Adaptor

4 Return ALP307 8mm QR Adaptor

5 HP Outlet A086B103 90 Deg HP Pipe Assy
6 - - (None)

7 Cable A086E955 Pump Cable – VDO 2

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

TIB 196/6 Issue 8, June 2018 (AT3531) © Hartridge Ltd., 2018 Page 6 of 8
VW_5WS40836 & 5WS40891
VDO Configuration
3
7 1 Mounting APB325_2 Mounting Plate
5

2 Coupling FP383 Coupling 25mm Taper

4 Port Extension (10mm

ALP365
Hose)
3 Supply +
+
ALP307
8mm QR Adaptor
4 Return ALP366 Adaptor Assy (10mm Hose)

5 HP Outlet A086B103 90 Deg HP Pipe Assy

6 - - (None)
Pump Cable – VDO 1
7 Cable A086E950
(FCV/VCV only)
Drive Direction R (CW) – viewed from pump drive end
Screws Pump to plate: 3 off M8x35

DV6C_5WS40893
VDO Configuration

1 Mounting APB351 Mounting Plate

FP383 Coupling
4 + +
2 Coupling ADC312 Bolt
+ +
ADC313 Spacer
ALP365 Port Extension (10mm Hose)
3 3 Supply + +
ALP307 8mm QR Adaptor
4 Return ALP307 8mm QR Adaptor

5 HP Outlet A086B103 (None)

6 - - (None)

7 Cable A086E950 Pump Cable – VDO 2

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

DV6C_5WS40894
VDO Configuration

4 1 Mounting APB351 Mounting Plate

FP383 Coupling
+ +
2 Coupling ADC312 Bolt
+ +
ADC313 Spacer
3 Supply ALP323 10mm QR Adaptor

3 4 Return ALP307 8mm QR Adaptor

5 HP Outlet A086B103 (None)

6 - - (None)

7 Cable A086E950 Pump Cable – VDO 2

Drive Direction R (CW) – viewed from pump drive end

Screws Pump to plate: 3 off M8x35

TIB 196/6 Issue 8, June 2018 (AT3531) © Hartridge Ltd., 2018 Page 7 of 8
3. Technical Information for Testing
AVM2-PC – Fuel Pressure Valve Operation

It is essential that the AVM2-PC Fuel Pressure Supply Valve is capable of maintaining a vacuum.
Prior to testing a VDO Common Rail pump the operation of the AVM2-PC Fuel Pressure Supply Valve must be
checked, using the following method (It is advised that personal protective clothing is worn): -
1. Close fuel pressure valve fully on AVM2-PC facia.
2. Fit ALP323 to the supply hose quick release connector.
3. Ensure that the exit of ALP323 is pointing into the drain area of the AVM2-PC test bench away from the
operator.
4. Turn the fuel on.
5. Monitor the fuel out of the supply pipe through ALP323 no oil should flow.
6. Open fuel pressure valve slowly (max 2 turns) on the AVM2-PC facia check for flow of fuel through
ALP323.
7. Close valve fully and check the fuel flow through ALP323 stops.
8. Turn fuel off.

If the fuel passes through ALP323 when the AVM2-PC valve is fully shut off it is defective and you should contact
your local distributor.

Angle of Pump Installation

The installation angle of for the each VDO Common Rail pump is very important, each pump must be installed
with cylinder 1 uppermost as shown in the diagram above. In most cases cylinder 1 is located next to PCV
electrical connection / pump return.

TIB 196/6 Issue 8, June 2018 (AT3531) © Hartridge Ltd., 2018 Page 8 of 8